High speed roller die press



y 23, 1964 A. L. WORRALL, JR, EI'AL 3, ,218

HIGH SPEED ROLLER DIE PRESS 4 Sheets-Sheet 1 Filed Oct. 27, 1961 3 HHH INVENTORS EARL E.WILL|AMS ASHTON L.WORRALLJR BY M &

ATTYS.

y 1964 A. WORRALL, JR., ETAL 3,

HIGH SPEED ROLLER DIE PRESS 4 Sheets-Sheet 2 Filed Oct. 27, 1961 INV T0 R'K'A REJR. SERP'EWLUA'MS %& M

ATTYS.

y 1964 A. WORRALL, JR., ETAL 3,142,218

HIGH spasm ROLLER on: PRESS,

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Filed Oct. 27 1961 ly 1964 A. L. WORRALL, JR.. ETAL 3,142,213

I HIGH SPEED ROLLER DIE PRESS 4 Sheets-Sheet 4 INVENTORS ASHTON L.WORRALL JR I BY EARL E.WIL.L.IAMS

ATTYS.

Filed Oct. 27, 1961 United States Patent 3,142,218 HIGH SPEED RQLLER DEE PRESS Ashton L. Worrall, J13, Cuyahoga Falls, and Earl E. Williams, North Canton, Ohio, assignors to The Falls Engrneenng & Machine Company, Guyahoga Falls, Ohio, a corporation of Ohio Filed Oct. 27, 1961, Ser. No. 148,184 Claims. (Cl. 83-510) This invention relates to a die cutting apparatus wherein a roll is moved over the die at a high speed for cutting material.

Heretofore it has been known to move a roll over a die to cut material placed on the die. In the prior machines the roll is supported by slide carriages positioned in window-like frame structures. The roll is driven through a long chain by a motor mounted on the frame structure. A gear on the roll and complementary rack on the frame enables the driven roll to move relative to the frame structure across the working material. In machines of this type the speed of the roll relative to the frame is limited by the drive means between the roll and the motor, and the starting torque of the motor. Also, the kinetic energy of the moving roll is absorbed in the drive mechanism or a friction brake associated therewith. It is not utilized to perform additional useful functions.

It is the general object of the invention to avoid and overcome the foregoing and other difficulties of and objections to the prior art apparatus by the provision of effective, efficient and inexpensive high speed roller die press.

An object of the present invention is to increase the speed of a roll of a roller die press.

Another object of the invention is to conserve the kinetic energy of the moving roll of a roller die Press.

A further object of the invention is to reduce the starting torque of the prime mover of a roller die press.

Another object of the invention is to compensate for the deflection of the roll of a roller die press as it passes over the Work material.

A further object of the invention is to increase the safety factor of a roller die press.

The high speed roller die press of the invention primarily comprises a pair of sub-frames adjustably mounted on a frame for vertical movement. Each sub-frame has a longitudinally extending opening terminated by end posts. Supported in the openings are slide carriages upon which the roll is rotatably mounted. A gear on the roll and a complementary rack on the sub-frame drives the roll on the sub-frame. Extending between and secured to the slide carriages are supports upon which a roll drive motor is secured. Mounted on each end post is a fluid cushioning cylinder and piston. Each piston has a portion adapted to engage the slide carriages as they approach the end post. A predetermined initial amount of fluid pressure is maintained in each cylinder. This fluid is compressed as the piston moves into the cylinder thereby absorbing the kinetic energy of the moving roll. A brake in the drive motor holds the carriages and roll against the increased pressure in the fluid cylinder. Releasing the brake transfers the potential energy of the fluid pressure to kinetic energy of the moving roll and slide carriages for the return passage.

The foregoing and other objects and advantages of the invention will be made more apparent as the specification proceeds.

For a better understanding of the principles of the invention reference should be had to the accompanying drawings, which illustrate a preferred embodiment, and wherein:

FIG. 1 is a side elevation of the high speed roller die press of the invention;

3,1422% Patented July 28., 1964 ice FIG. 2 is a front elevation of the apparatus of the invention taken along the line 2-2 of FIG. 1;

FIG. 3 is an enlarged fragmentary vertical section taken along line 3-3 of FIG. 2;

FIG. 4 is an enlarged fragmentary vertical section taken along the line 4-4 of FIG. 1;

FIG. 5 is an enlarged fragmentary vertical section taken along the line 5-5 of FIG. 2;

FIG. 6 is an enlarged fragmentary vertical section taken along the line 6-6 of FIG. 2;

FIG. 7 is a diagrammatic View showing the fluid pressure system of the apparatus of the invention; and

FIG. 8 is a diagrammatic view showing the die raising and lowering mechanism.

Referring now to the drawings there is shown in FIGS. 1 and 2 a frame 10 supporting the roller die press on a fixed surface. Laterally spaced sub-frames 12 and 14- are positioned on the frame by support posts 16 and sleeve brackets 18.

The support posts are fixed to the sub-frames and are slidably disposed in the sleeve brackets enabling the subframes to be vertically adjustable. The position of the support posts in the sleeve brackets is controlled by the threaded shafts or studs 20 and internally threaded adjusting members 24. Each shaft 20 extends vertically through a support 28 which is secured to support braces 30 of the frame 10. The adjusting members 22 and 24 are threaded on the shaft above and below the boss 28.

Formed integral with each adjusting member 24 is a wheel 26 which enables the adjusting members 24- to be rotated. Rotation of the adjusting members relative to the threaded shafts and supports 28 varies the vertical position of the shafts 20 thereby controlling the vertical position of the sub-frames relative to the frame. Locking wheels 22 threaded on shafts 20 releasably secure the shafts 29 in fixed positions.

As best seen in FIG. 1, each sub-frame has a longitudinally extending elongate opening or slot 32. Secured to the upper side of the slot or preferably formed integral with the sub-frame is an upper rail 34. A complementary rail 36 is secured to the lower side of the slot, or, as illustrated, is preferably formed integral with the subframe. Cup-shaped end posts 38 are secured by means of keys at) and bolts 42 to the sub-frames at each end of the opening 32. Channel-shaped brace members 44 are secured to the sub-frame about midway between the ends thereof to decrease their deflection. Suitable limit switches 45 are fastened to the sub-frame at each end of the slot 32, the purpose of which will be hereinafter explained.

Air cylinders 46 are secured by means of bolts 48 to the base portion of each end post 38. As best shown in FIG.

3, a piston 5% is slidably disposed in the horizontal air cylinder 46. The piston is provided with a number of sealing rings 52 between the piston Wall and the cylinder wall. Secured to the piston is a piston rod 54 which extends through the base of the end post 38 into the end portion of the opening 32. A suitable bearing 56 is employed between the piston rod 54 and the base of the end post 38. Threaded to the end of the piston rod 54 is a nut 58. The nut has chamfered ends and a flattened midportion to accommodate suitable fastening tools. Connected to the forward end of the cylinder and to the rearward end of the cylinder are conduits, as tubes or pipes, 60 and 62, the purpose of which will hereinafter be fully explained.

Positioned in the cup of the end post 38 is a circular spacer 64 and resilient cushion 66. The cushion and spacer form a safety bumper for the slide carriage 68.

A slide carriage 68 is positioned in the opening 32 in the subframes 12 and 14. As best shown in FIG. 4, each carriage has a pair of plates 70 and '72 which engage the opposite lateral margins of both the upper and lower rails 34 and 36. A plurality of upper rollers 74 and lower rollers 75 support the plates on the rails. Pins 76 rotatably mount the upper rolls between the plates. Eccentric pins 78 rotatably mount the lower rolls between the plates. Rotation of the eccentric pins 78 adjust the lower rollers 75 in a vertical direction. Bumper plates 80 are fastened to the ends of the slide carriage plate 72 by cap screws 82.

A hollow, hardened steel ground roll 84- extends across the machine. Each end of the roll 84 has a reduced diameter neck 86 which is rotatably journalled in the slide carriage plates 70 and 72. As shown in FIG. 3, a bearing 88 is positioned between the reduced diameter neck portion 86 of the roll 84 and the slide carriage plates '70 and 72.

As shown in FIG. 4, a gear 90 is secured by splines, keys or the like to each end of the roll 84. A rack 92 secured to a lower portion of the subframe engages the gear 90. The rack 92 extends the full length of the longitudinal opening 32. Rotation of the roll 84 will move the roll and slide carriages longitudinally in the opening. A sprocket 94 is fixedly secured to the roll 84 adjacent the gear 90.

Positioned on each side of the roll 84 are box-shaped support members 96. See FIG. 6. The support members are bolted or otherwise fixedly secured to the slide carriage plates 72. A horizontal plate 98 (FIGS. 4 and is secured by welding or the like to the top of the support members 96 adjacent one end thereof. A pair of vertically laterally spaced tabs 100 are fixed to an outer edge of the plate 98. A horizontal hinge plate 102 having vertically downwardly extending laterally spaced tabs 103 is positioned above plate 98. A hinge pin 104 extends through the tabs 100 and 103 to form an articulate joint. As shown in FIG. 5, vertically extending threaded rods 106 are positioned in the hinge plate 102 on the side opposite the tabs 103. Nuts 103 position the threaded rods in the plate 102 to angularly adjust the hinge plate relative to the plate 98.

Secured to the top of the hinge plate 102 by bolts 116 is a drive motor 110. The drive motor is, in a typical installation, a gear motor having an adjustable, springapplied, electro-magnetic released brake. Secured to the drive shaft of the motor is a sprocket 112 having a hub 114. A roller chain 118 or other flexible power transmitting medium engages the sprockets 94 and 112 to form a drive between the motor and the roll 84.

FIG. 6 shows the roll deflection compensator 120 which is positioned approximately midway between the ends of the roll. A pair of laterally spaced beams 122 transversely extend over the roll 84 and engage the top of the spaced support members 96. Brace plates 124 hold the beams 122 in spaced relation. The beams 122 are adjustably secured to the top of the support members 96 by means of bolts 126 and shims 128. Follower rollers 130 are rotatably mounted on the beams by shafts 132 and engage the outer surface of the roll 84 with suflicient force to initially deflect it so that when the roll is subjected to the deflection forces caused as the roll 84 passes over the work material the roll is substantially straight.

A die 136, see FIG. 2, is supported on a die receiving top plate 134. A base plate 138 fastened to a portion of the frame extends between the sub-frames 12 and 14 and below the roll 84. The base plate 138 has reinforcing flanges 139 and a flat top surface 140. The die receiving plate 134 is supported on raising posts 142. As shown in FIG. 8, a pair of gears 143 engage racks 145 on the raising posts 142. A drive shaft 144 interconnects the gears. A gear 148 is mounted on the drive shaft. A rack 149 driven by air cylinder 146 engages the gear 148. The air cylinder through the racks and gears provides the raising posts 142 with rapid vertical movement. The controls for the air cylinder are not illustrated on the drawing as they form no part of the present invention.

The air cylinder may be manually controlled or automatically controlled by the position of the slide carriages in the opening of the subframes.

The die 136 may be placed on the base plate 138 and a flat smooth plate positioned on the die receiving plate 134. In this instance, the die is fixed and the smooth surface is raised and lowered upon the work material.

FIG. 7 shows the fluid system which forms the dynamic air cushion for the moving roll assembly. Fluid under pressure from the source 152 is passed through filter 154 and pressure regulator 156 into conduit 157. The regulator 156 is adjustable to maintain approximately 15 p.s.i. pressure in the system. A pressure relief valve 158 is connected to the conduit 157. The conduit 157 is subsequently connected to the conduit 62 at the rear portion of the cylinders 46. Air flow control valves 160 are placed in the conduit 157 between the regulator 156 and the cylinders 46. The valves 160 function as check valves, as they do not allow the fluid to flow back from the cylinders into the conduit 157. Valves 160 may be provided with needle control which can be opened to bleed the cylinders 46. This needle control must be closed when the machine is running. A plug valve 162 and a pressure control switch 164 are connected to the conduit 157 downstream from the valves 160. The pressure control switch functions as a safety mechanism for the machine. If the pressure in line 157 falls below a predetermined amount, for example 15 p.s.i., the switch will break the motor control circuit to stop the machine.

A conduit 166 is connected to the conduit 60 on the forward end of the cylinder 46. A fluid accumulator 168 is connected by means of conduit 170 to the conduit 166. The conduit 170 has a check valve 172 which permits air to enter the accumulator after it is filtered by filter 176 and a check valve 174 which permits the fluid to leave the accumulator. A lubricator 173 provides the air with lubricating materials for the pistons 50 and the piston rods 54. A relief valve 180 and a plug valve 182 are connected to the accumulator. The relief valve vents excess pressure that may form in the accumulator. The plug valve enables all pressure to be relieved from the accumulator. The accumulator and the low pressure therein function to prevent the ingress of foreign materials into the cylinders.

The operation of the high speed roller die press will now be described. The material desired to be cut is placed on the flat top surface of the base plate 138 beneath the die 136. This may be accomplished manually or automatically by a feeding machine. The operation may be continuous or intermittent. The die 136 is lowered on the work material by the actuation of the motor 146 which drives the rack 149. Electrical energy is supplied to the gear motor 110. This energy releases the spring applied brake and starts the motor. When the brake is released the compressed fluid in cylinders 46 at one end of the apparatus forces each piston 50 and its rod 54 against the slide cariage 68 moving it longitudinally on the rails. The motor through the sprockets 94 and 112 and chain 118 rotates the roll 84. Since the gear 90 on the roll 84 engages the longitudinally extending rack 92 the rotating roll moves horizontally on the rails to effect the cutting action of the die against the work.

The rapidly moving roller assembly towards the end of the cutting stroke strikes the extended piston rods 54 and forces each piston 50 at the other end of the apparatus into the cylinders 46. Since the fluid under pressure in the cylinder 46 cannot escape because of the check valves 160, the kinetic energy of the moving roll assembly is converted or absorbed in the increased fluid pressure in the cylinders 46.

When the roll assembly engages the limit switch 45 the electrical power to the motor 110 is shut off, instantly applying the brake to hold the assembly in a fixed position relative to and at the end of the travel thereof in the sub-frames.

The die 136 is raised by the operation of the motor 146 and drive shaft 144 and raising posts 142. The cut work material is then removed from the base plate 138 and new material is placed thereon. The machine is now in position for a second cycle.

It should be understood, of course, that the foregoing disclosure relates to only a preferred embodiment of the invention and that it is intended to cover all changes and modifications of the invention herein chosen for purposes of disclosure, which do not constitute departures from the spirit and scope of the invention.

What is claimed is:

1. In combination, a carriage, means for driving the carriage with a reciprocating movement, means positioned at each end of the reciprocating movement for absorbing the forces required to stop the carriage and for returning the majority thereof to the carriage upon movement thereof in the opposite direction, and means for stopping the driving means for the carriage only after the means absorbing the forces has substantially stopped the carriage movement.

2. In combination, a carriage, means mounting the carriage for reciprocating movement, a reversible motor for driving the carriage in either direction on said mounting means, controllable air pressure means at each end of the mounting means for absorbing and storing the kinetic energy in the motor and carriage created by stopping and holding the carriage, means for stopping the motor after the kinetic energy from the carriage and motor has been absorbed and stored, and controllable means for driving the motor in reversed direction whereupon the controllable air pressure means storing the potential energy returns it to the carriage as kinetic energy to assist in overcoming the starting inertia of the carriage and the motor.

3. Material working apparatus including carriage means, means mounting the carriage means for reciprocating movement, means on the carriage means for performing work on material during movement of the carriage means, reversible motor means for moving the carriage means in either direction in its mounting means, controllable fluid, means in the path of final movement of the carriage means for absorbing and storing the energy required to stop the carriage means and the motor means and for returning this energy to the carriage means and the motor means when it is desired to drive the carriage in the opposite direction, means for stoppin the motor means only after the means absorbing the energy has substantially stopped the carriage and means for starting the motor means to drive the carriage in the opposite direction.

4. A roller die apparatus comprising a frame having a longitudinally extending opening, an upper and lower rail secured to the side walls of the frame forming the opening, end posts secured to the frame at the ends of the opening, a slide carriage supported on the rails, a roll having one end rotatably supported in the slide carriage, a gear secured to one end of the roll, a rack secured to the frame parallel to the rails and engageable with the gear, support means secured to the slide carriage, motor and brake means adjustably mounted on the support means, and drive means connecting the motor and brake means to the roll so that the motor and brake means will move the roll along the frame and rotate the roll as it is so moved, a controllable fluid cushion secured to each end post for absorbing and storing the energy of the moving carriage and driving motor, said cushion including a cylinder secured to each end post, a piston and piston rod disposed in each cylinder, the piston rod having a portion thereof adapted to engage the moving slide carriage, controllable means for maintaining in each fluid cylinder a predetermined initial amount of fluid pressure, said latter means including a check valve preventing the fluid in the cylinders from escaping so that movement of the pistons into the cylinders will increase the cylinder fluid pressure thereby absorbing the energy of the moving carriage and motor, and means for turning off the motor after a piston has been moved almost fully into its cylinder and to apply the brake means thereby applying the brake to hold the carriage and roll against the increased pressure.

5. A roller die apparatus comprising a frame, a pair of sub-frames, means adjustably mounting the sub-frames for vertical movement on the frame, a longitudinally extending opening in the sub-frames, an end post fixedly secured to the sub-frames at each end of the openings, an upper and lower rail integrally formed with the side walls of the sub-frames forming the opening, a pair of slide carriages longitudinally movable in the openings, roller means mounting one of the carriages in one opening and the other carriage in the other opening, a roll having each end rotatably mounted in the carriages, a gear secured to each end of the roll, a rack secured to the sub-frame parallel to the side walls of the openings and engageable with the gears, support and strengthening means extending between and secured to each of the slide carriages forming a box-like structure around the roll, motor and brake means adjustably mounted on the support means at one end thereof, drive means connecting the motor and brake means to the roll, a fluid cylinder secured to each end post, a piston positioned in each cylinder having a piston rod adapted to engage a portion of the slide carriage, means for maintaining a predetermined initial amount of fluid pressure in each fluid cylinder, and for preventing the escape of fluid from the cylinders so that movement of the pistons into the cylinders will absorb the energy of the moving carriages, roll, support means, and motor and brake means by increasing the fluid pressure therein, secondary cushioning means, consisting of a resilient material secured to the end post of the piston cylinders between the carriage and the end post of the frame, to absorb the energy of the carriage should the cylinders be completely depressed, and means for turning off the motor thereby applying the brake to hold the carriages and roll against the increased pressure.

References Cited in the file of this patent UNITED STATES PATENTS 1,192,353 Stevens July 25, 1916 1,192,354 Stevens July 25, 1916 2,091,789 Maussnest Aug. 31, 1937 2,121,003 Balfe June 21, 1938 2,217,060 Korsen Oct. 8, 1940 2,341,870 Johnston Feb. 15, 1944 2,467,276 Slater Apr. 12, 1949 2,772,736 Campbell Dec. 4, 1956 2,823,749 Chamberlain Feb. 18, 1958 2,846,005 Wilson Aug. 5, 1958 2,876,001 Strenstrom Mar. 3, 1959 3,057,241 Chambon Oct. 9, 1962 FOREIGN PATENTS 48,082 Germany Aug. 14, 1889 

1. IN COMBINATION, A CARRIAGE, MEANS FOR DRIVING THE CARRIAGE WITH A RECIPROCATING MOVEMENT, MEANS POSITIONED AT EACH END OF THE RECIPROCATING MOVEMENT FOR ABSORBING THE FORCES REQUIRED TO STOP THE CARRIAGE AND FOR RETURNING THE MAJORITY THEREOF TO THE CARRIAGE UPON MOVEMENT THEREOF IN THE OPPOSITE DIRECTION, AND MEANS FOR STOPPING THE DRIVING MEANS FOR THE CARRIAGE ONLY AFTER THE MEANS ABSORBING THE FORCES HAS SUBSTANTIALLY STOPPED THE CARRIAGE MOVEMENT. 